Adhesive projection points for roofing elements

ABSTRACT

A roofing element such as a concrete tile is provided that includes a body portion extending between a head end and a nose end. The body portion includes a lower surface, an upper surface, and a protrusion that is disposed substantially adjacent the nose end and extends downwardly from the lower surface. The protrusion is disposed on the lower surface such that when a nose end of a second roofing element is installed vertically above a head end of a first roofing element and overlapping by at least 3 inches, the protrusion of the second roofing element is positioned substantially above an aperture defined in the head end of the first roofing element. The protrusion reduces a distance between the aperture of the first roofing element and the nose end of the second roofing element, which increases the likelihood that the adhesive will securely join the first roofing element with the second roofing element.

BACKGROUND

1. Field of the Disclosure

The disclosure relates to an improvement in the design of roofingelements, and more particularly to roof tiles having a projectingstructure on the underside of a tile that provides an improvedconnection between tiles when secured together with adhesives.

2. Related Art

In the installation of concrete roofing elements, such as field tilesand trim tiles, a nose end of a second course tile is positioned tooverlap a head end of a first course tile to cover one or more aperturesin the head end of the first course tile. The apertures in the head endof the tiles receive fasteners such as nails or screws, for securing thetiles to the roof surface, and the overlap of the nose end of the secondcourse tile over the head end of the first course tile discourages rainand debris from leaking through the apertures. For example, wheninstalling field tiles, a second field tile is installed as part of asecond horizontal course of field tiles that are installed upward on asloped roof surface relative to a first horizontal course of field tilesof which a first field tile is a part. When installing trim tiles, whichare tiles that are typically installed along the ridge, rake, or edge ofthe roof surface, a second trim tile is installed such that the nose endof the second trim tile is stacked vertically above the head end of apreviously-installed first trim tile.

Good practice, or code regulations in certain jurisdictions, may requirethat installers apply an adhesive material onto the apertures at thehead end of each tile after the fastener has been engaged in theaperture, to secure the nose end of the next course of tiles to the headends of the tiles and to reduce the amount of rain and debris that maypenetrate below the next course tile and through the apertures. Applyingthe adhesive layer between courses of tiles increases material costs andinstallation time for the installers. In addition, a large amount ofadhesive may be required to secure the head end of the lower course tileto the nose end of the upper course tile. Thus, a need exists in the artfor a roofing element design that reduces the amount of adhesive usedbetween courses of roofing elements installed on the roof surface andensures that the applied adhesive secures the roofing elements together.

BRIEF SUMMARY

Various disclosed embodiments provide an improved roofing element thatreduces the amount of adhesive needed in a roof installation, reducesthe installation time for installers, and increases the likelihood thatthe adhesive applied will contact and securely join adjacent roofingelements. In particular, according to various embodiments, a number ofdifferent roofing elements are provided for installing on a sloped roof.Each of the roofing elements includes (1) a head end defining one ormore apertures therethrough for receiving a fastener to secure theroofing element to the sloped roof, (2) a nose end opposite the headend, and (3) a body portion extending between the head end and the noseend. The body portion includes a lower surface, an upper surfaceopposite the lower surface, and a protrusion. The protrusion is disposedadjacent the nose end and extends downwardly from the lower surface. Inparticular, the protrusion is disposed on the lower surface such thatwhen a nose end of a second roofing element is installed verticallyabove a head end of a first roofing element, the protrusion of thesecond roofing element is positioned above at least one of the one ormore apertures defined in the head end of the first roofing element. Theprotrusion reduces a distance between the aperture(s) and the nose endsuch that an amount of adhesive required to secure the head end of thefirst roofing element to the nose end of the second roofing element isreduced and the likelihood that the adhesive will contact and securelyjoin the nose end of the second roofing element with the head end of thefirst roofing element is increased.

In a particular embodiment, the body portion also defines a front edgesegment adjacent the nose end, and the front edge extends downwardlyfrom the lower surface and is shaped to substantially conform to theupper surface adjacent the head end. The protrusion is disposed inwardof the front edge segment toward the head end, preferably along alongitudinal axis of the roofing element. In a further embodiment, thefront edge segment extends a first distance from the lower surface andthe protrusion extends a second distance from the lower surface, and thefirst distance is greater than the second distance such that the frontedge segment substantially hides the protrusion when installed on theroof surface.

Building codes typically require the nose end of a tile in an uppercourse to overlap the head end of the next lower tile by at least apredetermined distance, currently three inches (3″). Therefore,according to one aspect, the protrusion is shaped and arranged on thelower tile surface such that even when the tiles overlap by apredetermined distance, which may be as much as 3″ or more, theprotrusion on the lower surface of the upper tile will be located abovethe aperture in the lower tile, that is, disposed for fastening theupper tile to the lower aperture with an adhesive. In other words, theprotrusion is spaced far enough from the nose end of the tile, orextends far enough from the nose end toward the head end of the tile,that the protrusion can be placed over the aperture of the next lowertile even when the upper tile overlaps the lower tile by thepredetermined distance, such as 3″ or more. Preferably the protrusion isdisposed on the lower surface at a location at least (3-D) inches fromthe nose end, wherein D is a distance between the aperture and the headend.

According to various embodiments, the roofing elements includes trimtiles, such as ridge tiles for installing along a ridge of a sloped roofsurface or rake tiles for installing along a rake of a sloped roofsurface, or field tiles, which are installed on the main portion of theroof surface. In addition, the roofing elements may be formed fromconcrete or other suitable material, such as wood, slate, metal, orpolymeric material.

According to other aspects, a mold pallet and a manufacturing method formanufacturing the files will also be described.

Other features and advantages will become apparent from the followingdescription of embodiments which refers to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are longitudinal cross-sectional views showing twoinstalled ridge tiles in two different relative positions;

FIG. 3 is a perspective view of a lower surface of a trim tile accordingto one embodiment of the invention;

FIG. 4 is a perspective view of a lower surface of a trim tile accordingto another embodiment of the invention;

FIG. 5 is a perspective view of a lower surface of a trim tile accordingto yet another embodiment of the invention;

FIG. 6 is a perspective view of the upper surface of a field tileaccording to another embodiment of the invention;

FIG. 7 is a bottom plan view of the lower surface of the field tileshown in FIG. 6;

FIG. 8 is an exploded view of a mold pallet, a roller, and a slipper formanufacturing the trim tile shown in FIG. 3 according to variousembodiments of the invention;

FIG. 9 is an exploded view of a mold pallet, a roller, and a slipper formanufacturing the ridge trim tile shown in FIG. 4 according to variousembodiments of the invention;

FIG. 10 is an exploded view of a mold pallet, a roller, and a slipperfor manufacturing the rake trim tile shown in FIG. 5 according tovarious embodiments of the invention; and

FIG. 11 is an exploded view of two trim tiles according to theembodiment shown in FIG. 3, installed relative to each other accordingto one embodiment of the installation method.

DETAILED DESCRIPTION

Various embodiments have been developed to provide an improved roofingsystem and roofing element.

In the embodiments, a roofing element is provided wherein at least oneprotrusion extends downwardly from the lower surface of the roofingelement, to reduce the distance below the nose end of a second roofingelement installed vertically above the head end of a first roofingelement. The reduced distance between the roofing elements reduces anamount of adhesive to be applied between a head end of an upper surfaceof the first roofing element and the lower surface of the nose end ofthe second roofing element to secure the roofing elements together, andincreases the likelihood that the adhesive will contact and secure theroofing elements together. The protrusion is shaped and arranged on thelower tile surface such that even when the tiles overlap by 3″, or more,the protrusion on the lower surface of the upper tile will beaccessible, located above the aperture in the lower tile, for fasteningthe upper tile to the lower aperture with an adhesive. Preferably theprotrusion is disposed on the lower surface at a location at least (3-D)inches from the nose end, wherein D is a distance between the apertureand the head end.

Various embodiments provide roofing elements (e.g., field tiles and trimtiles) having protrusions that reduce the distance between the nose endof a second roofing element installed vertically above the head end of afirst roofing element, which reduces the amount of adhesive to beapplied between courses of roofing elements during installation on asloped roof surface and increases the likelihood that the adhesive willcontact and secure the roofing elements together. According to variousembodiments, the roofing elements include trim tiles, such as ridgetiles for installing along a ridge of a sloped roof surface or raketiles for installing along a rake of a sloped roof surface, or fieldtiles, which are installed on the main portion of the roof surface. Theroofing elements may be formed from concrete or other suitable material,such as clay, concrete, wood, slate, metal, or polymeric material.

FIG. 1 shows two installed ridge tiles 100, 102 in a longitudinalcross-section. The first ridge tile 100 lays with its head end 104 on aridge tree 106 and with its nose end (not shown) it overlaps aneighboring ridge tile. Close to its head end 104 the first ridge tile100 is provided with a nail hole 108. The first ridge tile 100 issecured on the ridge tree 106 with a nail 110. The nail 110 is insertedinto the first ridge tile's nail hole 108 and driven into the woodenridge tree 106. The head 112 of the nail 110 covers the nail hole 108,but stands up from the upper surface 114 of the first ridge tile 100 andcannot prevent the penetration of water through the nail hole 108. Tosolve this problem, it is a common practice to apply an adhesive 116,such as a plastic adhesive, on the nail head 112 to seal the nail hole108 against water penetration.

The second ridge tile 102 has a design which is identical with that ofthe first ridge tile 100. The second ridge tile 102 has a head end 118with a nail hole 120 and a nose end 122 that overlaps the head end 104of the fixed first ridge tile 100. The ridge tiles 100, 102 areinstalled with a maximum overlap of greater than a predetermineddistance, for example 3″. In the overlapping area the second ridge tile102 is provided with a protrusion 124 projecting from the lower surface126. Due to the projecting protrusion 124 of the second ridge tile 102the distance 128 between the protrusion 124's surface 130 and the uppersurface 114 of the fixed first ridge tile 100 is significantly reducedcompared to the distance 132 between the lower surface 126 of the secondridge tile 102 and the upper surface 114 of the first ridge tile 100.Therefore less adhesive 116 is required to bridge the gap between thetwo ridge tiles 100, 102.

The distance 128 should be at least 1 mm, preferably 2 mm. This willensure that the protrusion 124 is not in direct contact with the nail110's head 112. During the installation of the second ridge tile 102 itsprotrusion 124 is pressed onto the plastic adhesive 116 applied to thenail 110's head 112. Therefore the adhesive 116 penetrates into the nailhole 108 and encapsulates the nail 110's head 112. Furthermore theadhesive 116 forms a large-area adherent, which ensures a strong glueconnection 134 between the ridge tiles 100, 102 at the protrusion 124.

FIG. 2 shows the two installed ridge tiles 100, 102 known from FIG. 1 ina longitudinal section, but installed with a minimum overlap which,according to building codes, will be at least a predetermined distance,for example 3″. When the ridge tiles 100, 102 are laid with the minimumoverlap the glue connection 134 is formed close to the weatherbar 136.If the ridge tiles 100, 102 are laid with the maximum overlap—as shownin FIG. 1—the glue connection 134 is formed close to the inner edge 138of the protrusion 124. To ensure in the light of the variable overlapthat there will be always a match between the protrusion 124 of thesecond ridge tile 102 and the nail hole 108 of the first ridge tile 100,the protrusion 124 has an extension X in the longitudinal direction(nose end to head end) that is at least long enough to permit an overlapof the predetermined distance required by building codes.

In other embodiments, the protrusion need not extend continuously upwardfrom the nose end toward the head end of the tile as shown in FIGS. 1and 2. Instead, one or a plurality of discontinuous protrusions may beprovided. At least one protrusion is spaced far enough from the nose endof the tile, or extends far enough from the nose end towards the headend of the tile, so that the protrusion can be placed over the apertureof the next lower tile even when the upper tile overlaps the lower tileby 3″ or more.

The dimensions of each protrusion need only be large enough to cover thecorresponding aperture.

The technical function of the protrusion 124 and the achieved commercialbenefits are identical with the protrusions shown in the other FIGS. 3,4, 5 and 6.

In the embodiment shown in FIG. 3, a trim tile 10 is provided that canbe used along a ridge of a sloped roof surface or along the rake oredges of the roof surface. The trim tile 10 includes a head end 11, anose end 12, and a body portion 13 that extends between the head end 11and nose end 12. A cross section of the body portion 13 transverse to alongitudinal axis A of the tile 10 is generally arcuate-shaped, and thebody portion 13 comprises a lower surface 15, an upper surface 19opposite the lower surface 15, and a protrusion 16 that is disposedproximate the nose end 12 and extends downwardly from the lower surface15. The protrusion 16 is disposed on the lower surface 15 such that whenthe nose end 12 of a second trim tile 10 is installed vertically abovethe head end 11 of a first trim tile 10, the protrusion 16 of the secondtrim tile 10 is positioned substantially above an aperture 14 defined inthe head end 11 of the first trim tile 10. The protrusion 16 reduces thedistance between the nose end 12 of the second trim tile 10 when thesecond trim tile 10 is installed vertically above the aperture 14 of thehead end 11 of the first trim tile 10, which reduces an amount ofadhesive to be applied between the aperture 14 and the nose end 12 tosecure the nose end 12 of the second trim tile 10 to the head end 11 ofthe first trim tile 10 and increases the likelihood that the adhesivewill contact and secure the second trim tile 10 to the first trim tile10. In the embodiment shown in FIG. 3, the head end 11 defines oneaperture 14 and the body portion 13 comprises one protrusion 16, but itshould be understood by those of ordinary skill in the art that invarious embodiments of the invention, the tile 10 may define more thanone aperture 14 and more than one corresponding protrusion 16 forpositioning above the apertures 14 during installation with at least 3″of overlap as described above.

In a further embodiment, the tile 10 further comprises a front edgesegment 18 adjacent the nose end 12 that extends downwardly from thelower surface 15 and is shaped to substantially conform to the uppersurface 19 adjacent the head end 11. The protrusion 16 is disposedinward of the front edge segment 18 toward the head end 11 along alongitudinal axis A of the trim tile 10. The front edge segment 18extends further from the lower surface 15 than the protrusion 16 suchthat the front edge segment 18 substantially hides the protrusion 16 andadhesive below the tile 10 when installed on the roof surface with atleast 3″ of overlap as described above.

Another exemplary roofing element is shown in FIG. 4. According to theembodiment shown, a trim tile 20 is provided that can be used along aridge of a sloped roof. The trim tile 20 includes a head end 21, a noseend 22, and a body portion 23 that extends between the head end 21 andnose end 22. The body portion 23 comprises three walls such that a firstwall 53 a and third wall 53 c extend outwardly and at an angle from thesecond wall 53 b. When installed, the second wall 53 b is positionedvertically atop the ridge of the roof, and the first wall 53 a and thethird wall 53 c extend downwardly from the second wall 53 b toward thesloped roof surface and field tiles installed thereon. The walls 53 a-cdefine a lower surface 25 of the body portion 23 and an upper surface 29of the body portion 23 that is opposite the lower surface 25. The secondwall 53 b defines an aperture 24 adjacent the head end 21 for securingthe trim tile 20 to the roof surface, and the second wall 53 b defines aprotrusion 26 that is disposed substantially adjacent the nose end 22and extends downwardly from the lower surface 25. The protrusion 26 isdisposed on the lower surface 25 such that when the nose end 22 of asecond trim tile 20 is installed vertically above the head end 21 of afirst trim tile 20, the protrusion 26 of the second trim tile 20 ispositioned substantially above the aperture 24 defined in the head end21 of the first trim tile 20. The protrusion 26 reduces the distancebetween the nose end 22 of the second trim tile 20 when the second trimtile 20 is installed vertically above the aperture 24 of the head end 21of the first trim tile 20, which reduces an amount of adhesive to beapplied between the aperture 24 and the nose end 22 to secure the noseend 22 of the second trim tile 20 to the head end 21 of the first trimtile 20 and increases the likelihood that the adhesive will contact andsecure the second trim tile 20 to the first trim tile 20 with at least3″ of overlap as described above.

In the embodiment shown in FIG. 4, the head end 21 defines one aperture24 and the lower surface 25 defines one protrusion 26, but it should beunderstood by those of ordinary skill in the art that in variousembodiments, the tile 20 may define more than one aperture 24 (e.g., onthe second wall 53 b or on one or more of the other walls 53 a, 53 c)and corresponding protrusion 26 for positioning above the aperture 24during installation.

In a further embodiment, the three walls 53 a-c also define a front edgesegment 28 disposed adjacent the nose end 22, and the front edge segment28 extends downwardly from the lower surface 25 and is shaped tosubstantially conform to the upper surface 29 adjacent the head end 21.The protrusion 26 is disposed inward of the front edge segment 28 towardthe head end 21 along a longitudinal axis B of the trim tile 20. Thefront edge segment 28 extends further from the lower surface 25 than theprotrusion 26 such that the front edge segment 28 substantially hidesthe protrusion 26 and adhesive below the tile 20 when installed on theroof surface.

Yet another exemplary roofing element is shown in FIG. 5. According tothe embodiment shown, a trim tile 30 is provided that can be installedalong a ridge or a rake or edge of the roof surface. The trim tile 30includes a head end 31, a nose end 32, and a body portion 33 thatextends between the head end 31 and nose end 32. The body portion 33comprises two walls such that a first wall 63 a and a second wall 63 bare formed together along a common longitudinal edge (or interface) ofthe first wall 63 a and the second wall 63 b at an angle substantiallyequal to 90°. The walls 63 a, 63 b define a lower surface 35 of the bodyportion 32 and an upper surface 39 of the body portion 33 that isopposite the lower surface 35. The interface between the first wall 63 aand the second wall 63 b defines a ridge aperture 34 adjacent the headend 31 for securing the trim tile 30 to the ridge of the roof surface.The body portion 33 further defines a protrusion 36 that extendsdownwardly from the lower surface 35 and is disposed proximate theinterface between the first wall 63 a and the second wall 63 b andsubstantially adjacent the nose end 32. In particular, the protrusion 36is disposed on the lower surface 35 such that when the nose end 32 of asecond trim tile 30 is installed vertically above the head end 31 of afirst trim tile 30, the protrusion 36 of the second trim tile 30 ispositioned substantially above the aperture 34 defined in the head end31 of the first trim tile 30. The protrusion 36 reduces the distancebetween the nose end 32 of the second trim tile 30 when the second trimtile 30 is installed vertically above the aperture 34 of the head end 31of the first trim tile 30 with at least 3″ of overlap as describedabove, which reduces an amount of adhesive to be applied between theaperture 34 and the nose end 32 to secure the nose end 32 of the secondtrim tile 30 to the head end 31 of the first trim tile 30 and increasesthe likelihood that the adhesive will contact and secure the second trimtile 30 to the first trim tile 30.

In the embodiment shown in FIG. 5, the head end 31 defines one aperture34 and the body portion 33 comprises one protrusion 36, but it should beunderstood by those of ordinary skill in the art that in variousembodiments of the invention, the tile 30 may define more than oneaperture 34 (e.g., along the interface between the first wall 63 a andsecond wall 63 b or on the first wall 63 a or the second wall 63 b) andcorresponding protrusion 36 for positioning above the aperture 34 duringinstallation.

In a further embodiment, the first wall 63 a and the second wall 63 bcomprise a front edge segment 38 that is adjacent the nose end 32. Thefront edge segment 38 extends downwardly from the lower surface 35 andis shaped to substantially conform to the upper surface 39 adjacent thehead end 31. The protrusion 36 is disposed inward of the front edgesegment 38 toward the head end 31 along a longitudinal axis C of thetile 30. The front edge segment 38 extends further from the lowersurface 35 than the protrusion 36 such that the front edge segment 38substantially hides the protrusion 36 and adhesive below the tile 30when installed on the roof surface.

In the embodiment shown in FIGS. 6 and 7, a field tile 40 is providedthat can be installed along the main portion of the sloped roof. Thefield tile 40 includes a head end 41, a nose end 42, and a body portion43 that extends between the head end 41 and nose end 42. The bodyportion 43 comprises a lower surface 45 and an upper surface 49 oppositethe lower surface 45, and the upper surface 49 is substantially flat.The body portion 43 further comprises at least one protrusion 46 that isdisposed substantially adjacent the nose end 42 and extends downwardlyfrom the lower surface 45. The protrusion 46 is disposed on the lowersurface 45 such that when the nose end 42 of a second field tile 40 isinstalled vertically above the head end 41 of a first field tile 40, theprotrusion 46 of the second field tile 40 is positioned substantiallyabove at least one aperture 44 defined in the head end 41 of the firstfield tile 40 with at least 3″ of overlap as described above. Theprotrusion 46 reduces the distance between the nose end 42 of the secondfield tile 40 when the second field tile 40 is installed verticallyabove the aperture 44 of the head end 41 of the first field tile 40,which reduces an amount of adhesive to be applied between the aperture44 and the nose end 42 to secure the nose end 42 of the second fieldtile 40 to the head end 41 of the first field tile 40 and increases thelikelihood that the adhesive will contact and secure the second fieldtile 40 to the first field tile 40. In the embodiment shown in FIGS. 6and 7, the head end 41 defines two apertures 44 and the body portion 43comprises two protrusions 46 that correspond to each aperture 44, but itshould be understood by those of ordinary skill in the art that invarious embodiments of the invention, the field tile 40 may define onlyone aperture 44 and one corresponding protrusion 46 or more than twoapertures 44 and corresponding protrusions 46 for positioning above theapertures 44 during installation. In addition, various embodiments mayprovide one or more elongated protrusions across the nose end that areconfigured for spanning across the one or more apertures defined by thelower course tile upon installation, for example, or other suitableconfigurations.

In a further embodiment, the body portion 43 also comprises a front edgesegment 48 adjacent the nose end 42, and the front edge segment 48extends downwardly from the lower surface 45 and is shaped tosubstantially conform to the upper surface 49 adjacent the head end 41.The protrusion 46 is disposed inward of the front edge segment 48 towardthe head end 41 along a longitudinal axis D of the field tile 40. Thefront edge segment 48 extends further from the lower surface 45 than theprotrusion 46 such that the front edge segment 48 substantially hidesthe protrusion 46 and adhesive below the tile 40 when installed on theroof surface.

Installation Process

FIG. 11 illustrates an exemplary installation of trim tiles, such as thetrim tiles 10 shown in FIG. 3, along a ridge 105 of a sloped roofsurface 100 according to various embodiments. The first trim tile 10 ais positioned such that its nose end 12 is adjacent an edge 102 of theridge 105 of the roof 100 and its head end 11 is inward of the edge 102.The first trim tile 10 a is secured to the ridge 105 of the roof surface100 by engaging a fastener (not shown) through the aperture 14 (notshown) in the head end 11 of the tile 10 and into the roof 100. Adhesive17 is then applied onto the upper surface 19 of the first tile 10 aabove the fastener, and the protrusion 16 at the nose end 12 of a secondtile 10 b is positioned substantially vertically above the aperture 14and adhesive 17 of the first tile 10 a. The head end 11 of the secondtile 10 b positioned further inward along the ridge 105 of the roofsurface 100 and is secured to the ridge using another fastener. Theprocess continues until trim tiles 10 have been installed along thelength of the ridge 105.

Manufacturing Process

The roofing elements described in FIGS. 1 to 7 can be formed in clay bya pressing process or formed in concrete by an extrusion process. Toproduce concrete roof tiles an endless ribbon of green (not yethardened) concrete is extruded on an endless string of mold pallets.FIGS. 8-10 show single mold pallets 70, 80, 90 suitable to formdifferently shaped concrete tiles. The upper surface of each mold pallet70, 80, 90 defines the shape of the lower surface of the correspondingtrim tile 10, 20, 30. A roller 72, 82, 92 is positioned above the stringof mold pallets 70, 80, 90 and has a surface that is substantially theshape of the upper surface of the mold pallet 70, 80, 90. To force thegreen concrete between the roller 72, 82, 92 and the mold pallet 70, 80,90, the roller 72, 82, 92 is spun at a speed slightly faster than thespeed at which the mold pallet 70, 80, 90 is moving below the roller 72,82, 92. The green concrete is compressed between the roller 72, 82, 92and the mold pallet 70, 80, 90 to form a rough shape of the tile 10.Next, the mold pallet 70, 80, 90 moves below a slipper 74, 84, 94 whichforms the upper surface of the tile 10, 20, 30 in more detail and withinspecified tolerances.

To provide each concrete tile 10, 20, 30 with a protrusion the moldpallet 70, 80, 90 is provided at the nose end with a cavity 200, 210,220 forming the protrusion.

When the molds pass the roller, the fresh concrete is pressed by theroller into the cavities of the molds, which form the reverse of theroof tile including weather bars, hanging nibs, the describedprotrusions and/or other surface features. Simultaneously the rollerforms the upper surface of the roof tile. When the molds pass theslipper behind the roller, the upper surface of the roof-tile shapedconcrete ribbon is further compressed by the slipper. This improvesfurther the compaction and surface smoothness of the roof tiles prior tothe coating application.

After the forming process the mould pallets are conveyed into a cuttingdevice in which the compressed concrete ribbon will be chopped intosingle concrete tiles so that each mold pallet bears a single concretetile. Next, the concrete tiles will be cured, released from the moldpallets and packed for the shipping.

It should be understood that the shapes of the mold pallets 70, 80, 90,rollers 72, 82, 92, and slippers 74, 84, 94 may be modified tomanufacture tiles having differently shaped profiles.

CONCLUSION

It may be seen that the various disclosed embodiments overcomedeficiencies in the prior art by providing roofing tiles that reduce thedistance between the aperture of the first course tile and a portion ofthe nose end of the second course tile installed vertically above theaperture, even with an overlap of 3″ or more. Reducing the distancereduces the amount of adhesive needed between roofing elements duringinstallation to secure the roofing elements together and increases thelikelihood that the adhesive applied will contact and secure theadjacent roofing elements together. While various embodiments have beendescribed in specific detail, it should be understood that the inventionis not limited to the disclosed embodiments, and that many variationsand modifications may be effected within the full spirit and scope ofthe invention.

1. A roofing element for installing on a sloped roof, said roofingelement comprising: a head end defining one or more aperturestherethrough for receiving a fastener to secure said roofing element tosaid sloped roof; a nose end opposite said head end; a body portionextending between said head end and said nose end; and said body portioncomprising a lower surface, an upper surface opposite said lowersurface, and a protrusion, said protrusion disposed substantiallyadjacent said nose end and extending downwardly from said lower surface,wherein said protrusion is disposed on said lower surface such that whena nose end of a second roofing element is installed vertically adjacenta head end of a first roofing element and overlapping by at least apredetermined distance, said protrusion of said second roofing elementis positioned substantially above said one or more apertures defined insaid head end of said first roofing element, and wherein said protrusionis configured to reduce a distance between said one or more aperturesand said nose end lower surface such that an amount of adhesive neededto secure said nose end of said second roofing element to said head endof said first roofing element is reduced and a likelihood that theadhesive will contact and securely join said nose end of said secondroofing element with said head end of said first roofing element isincreased.
 2. The roofing element of claim 1, comprising a trim element.3. The roofing element of claim 2, comprising a ridge element, saidridge element configured for being installed along a ridge of saidsloped roof.
 4. The roofing element of claim 3, wherein: said ridgeelement comprises a first wall, a second wall, and a third wall, saidfirst wall and said third wall extend substantially outwardly anddownwardly from opposite edges of said second wall.
 5. The roofingelement of claim 3, wherein a cross-section of said ridge elementtransverse to a longitudinal axis of said ridge element is substantiallyarcuate in shape.
 6. The roofing element of claim 2, comprising a rakeelement.
 7. The roofing element of claim 6, wherein said rake elementcomprises a first wall and a second wall, said first wall and saidsecond wall being formed together along a common longitudinal edge ofeach of said first wall and said second wall at an angle substantiallyequal to 90°.
 8. The roofing element of claim 1, comprising a fieldtile.
 9. The roofing element of claim 1, wherein each of said roofingelements is formed of a concrete material.
 10. The roofing element ofclaim 1, wherein said body portion further comprises a front edgesegment disposed adjacent said nose end, said front edge segmentextending downwardly from said lower surface and being shaped tosubstantially conform to said upper surface adjacent said head end, saidprotrusion being disposed inward of said front edge segment toward saidhead end along a longitudinal axis of said roofing element.
 11. Theroofing element of claim 10, wherein said front edge extends a firstdistance from said lower surface and said protrusion extends a seconddistance from said lower surface, wherein said first distance is greaterthan said second distance.
 12. The roofing element of claim 1, whereinsaid predetermined distance is three inches.
 13. The roofing element ofclaim 12, wherein said protrusion is disposed on said lower surface at alocation at least (3-D) inches from said nose end, wherein D is adistance between said aperture and said head end.
 14. The roofingelement of claim 1, wherein said protrusion is disposed on said lowersurface at a location at least (3-D) inches from said nose end, whereinD is a distance between said aperture and said head end.
 15. The roofingelement of claim 1, comprising a plurality of protrusions spaced fromeach other along a longitudinal direction of said roofing element. 16.The roofing element of claim 1, comprising a plurality of protrusionsspaced from each other along a lateral direction of said roofingelement.
 17. The roofing element of claim 1, wherein said protrusionextends continuously from said nose end along a longitudinal directionof said roofing element.
 18. The roofing element of claim 1, whereinsaid protrusion protrudes from said lower surface at a location spacedaway from said nose end and separated from said nose end by a portion ofsaid lower surface that does not protrude from said lower surface. 19.The roofing element of claim 18, wherein said protrusion extends on saidlower surface along a lateral direction of said roofing element.
 20. Amold pallet for manufacturing a roofing element, for installing on asloped roof, said mold pallet having an upper surface configured formolding a roofing element comprising: a head end defining one or moreapertures therethrough for receiving a fastener to secure said roofingelement to said sloped roof; a nose end opposite said head end; a bodyportion extending between said head end and said nose end; and said bodyportion comprising a lower surface, an upper surface opposite said lowersurface, and a protrusion, said protrusion disposed substantiallyadjacent said nose end and extending downwardly from said lower surface,wherein said protrusion is disposed on said lower surface such that whena nose end of a second roofing element is installed vertically adjacenta head end of a first roofing element and overlapping by at least apredetermined distance, said protrusion of said second roofing elementis positioned substantially above said one or more apertures defined insaid head end of said first roofing element, and wherein said protrusionis configured to reduce a distance between said one or more aperturesand said nose end lower surface such that an amount of adhesive neededto secure said nose end of said second roofing element to said head endof said first roofing element is reduced and a likelihood that theadhesive will contact and securely join said nose end of said secondroofing element with said head end of said first roofing element isincreased.
 21. The roofing element of claim 20, wherein saidpredetermined distance is three inches.
 22. The roofing element of claim21, wherein said protrusion is disposed on said lower surface at alocation at least (3-D) inches from said nose end, wherein D is adistance between said aperture and said head end.
 23. The roofingelement of claim 20, wherein said protrusion is disposed on said lowersurface at a location at least (3-D) inches from said nose end, whereinD is a distance between said aperture and said head end.
 24. A method ofmanufacturing a roofing element, said method comprising the steps of:providing a roofing element having a head end, a nose end opposite saidhead end, an upper surface, and a lower surface opposite said uppersurface, and providing a protrusion disposed substantially adjacent saidnose end and extending downwardly from said lower surface; saidprotrusion being disposed on said lower surface such that when a firstroofing element is installed on a sloped roof, by inserting a fastenerthrough at least one aperture in said head end and into said sloped roofand a second roofing element is installed substantially verticallyadjacent the first roofing element and overlapping by at least apredetermined distance, said protrusion of the second roofing element ispositioned vertically above said fastener and said aperture of the firstroofing element.
 25. The method of claim 24, further comprising thesteps of: providing a front edge disposed adjacent said nose end andextending downwardly from said lower surface, said front edge beingshaped to substantially conform to said upper surface adjacent said headend, and said protrusion being disposed inward of said front edge towardsaid head end along a longitudinal axis of said roofing element.
 26. Themethod of claim 25, wherein said front edge extends a first distancefrom said lower surface and said protrusion extends a second distancefrom said lower surface, wherein said first distance is greater thansaid second distance.
 27. The method of claim 24, said roofing elementbeing provided by the steps of: providing a mold pallet, the mold pallethaving an upper surface shaped for molding a lower surface of said headend, nose end and body portion, including a cavity in said upper surfaceshaped for forming said protrusion; compressing green concrete into saidmold pallet; and curing said green concrete.
 28. The method of claim 27,wherein said green concrete is pressed into a series of said moldpallets, and further comprising the step of cutting said green concretebetween said mold pallets.